KTM 50 MINI ADVENTURE Owner's manual

Brand: KTM

Model: 50 MINI ADVENTURE

Category: Motorcycles

Type: Owner's manual

This manual is also suitable for

OWNERS HANDBOOK

MANUEL D’UTILISATION

MANUAL DE INSTRUCCIONES

Art.Nr. 3.205.81 7/99

2000

50 MINI ADVENTURE, 50 SX JUNIOR, 50 JR ADVENTURE, 50 SX SENIOR, 50 SR ADVENTURE

BEDIENUNGSANLEITUNG

ENGLISH

Please insert below the series numbers of the motorcycle

Frame number

Engine number

Stamp of dealer

IMPORTANT

PLEASE READ THIS MANUAL THOROUGHLY BEFORE LETTING YOUR

YOUNGSTER RIDE THE MOTORCYCLE FOR THE FIRST TIME. THIS MANUAL

CONTAINS IMPORTANT INFORMATION AND RECOMMENDATIONS THAT

WILL HELP YOU AND YOUR YOUNGSTER TO OPERATE AND HANDLE THE

MOTORCYCLE PROPERLY.

IN THE INTEREST OF EVERYBODY INVOLVED, WE URGE YOU TO PAY PARTI-

CULAR ATTENTION TO INSTRUCTIONS AND INFORMATION MARKED AS

FOLLOWS:



WARNING



IGNORING THESE INSTRUCTIONS, CAN ENDANGER YOUR BODY

AND YOUR LIFE.

CAUTION

IGNORING THESE INSTRUCTIONS COULD CAUSE DAMAGE TO

PARTS OF THE MOTORCYCLE OR THAT THE MOTORCYCLE IS

NOT ROAD-SAFE ANYMORE.

KTM S

PORTMOTORCYCLE

RESERVES THE RIGHT TO MODIFY ANY EQUIPMENT

TECHNICAL SPECIFICATIONS

COLORS

MATERIALS

SERVICES OFFERED AND RENDERED

AND THE LIKE SO AS TO ADAPT THEM TO LOCAL CONDITIONS WITHOUT

PREVIOUS ANNOUNCEMENT AND WITHOUT GIVING REASONS

OR TO CANCEL ANY OF THE ABOVE ITEMS WITHOUT SUBSTI

TUTING THEM WITH OTHERS

. I

T SHALL BE ACCEPTABLE TO STOP MANUFACTURING A CERTAIN MODEL WITHOUT PREVIOUS

ANNOUNCEMENT

. I

N THE EVENT OF SUCH MODIFICATIONS

PLEASE ASK YOUR LOCAL

KTM

DEALER FOR INFORMATION

E SHALL NOT BE HELD LIABLE FOR ANY PRINTING ERRORS

ENGLISH

Introduction

Now you own a modern motorcycle that you and your youngster will certainly enjoy, provided

that you service and maintain it properly. This manual contains important information on the

operation and maintenance of your new KTM motorcycle. It went to press describing your

model’s latest state of development. Nevertheless, the descriptions may deviate slightly from the

current design as our motorcycles are permanently improved.

Maybe you are one of those riders who have acquired good technical skills and can perform

many of the maintenance tasks themselves using the instructions contained in this manual. If this

is not the case, please keep in mind that the maintenance tasks marked with an asterisk (*) in

the chapter „Maintenance of chassis and engine“ should rather be performed by a KTM dealer

to protect you and your youngster.

Please strictly observe the prescribed running-in periods and inspection and maintenance inter-

vals. Compliance with these instructions will significantly prolong the life of your motorcycle.

Maintenance work should only be performed by a KTM dealer.

When special needs arise, please contact a KTM dealer, who will seek the assistance of the KTM

importer if necessary.

PARENTS SHOULD KEEP IN MIND that the safety of their youngsters always depends on the

efforts made by the parents to ensure that the motorcycle is kept in good working order and

only used on safe terrains. Nevertheless, driving the motorcycle, like driving any other vehicle,

involves a potential risk. Therefore, please make sure that all fundamental precautions are taken.

Please also read the „INFORMATION ON SAFE DRIVING FOR PARENTS“ on page 4.

Riding an off-highway motorcycle is a wonderful form of outdoor recreation and we certainly

hope that you and your youngsters will enjoy it to the full. However, this enjoyable outdoor

activity can cause environmental problems or lead to conflicts with other people. Responsible use

of the motorcycle will prevent such problems and conflicts. You can contribute to securing the

future of motorcycling by making sure that you and your youngsters only use the motorcycle

within the limits established by the applicable laws, making environmental protection one of

your top priorities and never violating other people’s rights.

In this spirit, we hope that you and your youngsters will always safely enjoy your motorcycle!

KTM SPORTMOTORCYCLE AG

5230 MATTIGHOFEN, AUSTRIA

Attachments

: 1 spare parts manual chassis 1 spare parts manual engine

KTM Austria’s certificate of achievement for its Quality System ISO 9001 is the beginning of an on-going

total re-engineering quality plan for a brighter tomorrow.

ENGLISH

Page

IMPORTANT INFORMATION ON SAFE DRIVING FOR PARENTS ............4

SERIAL NUMBER LOCATIONS ..................................................................5

Chassis number .....................................................................................5

Engine number, engine type..................................................................5

OPERATION INSTRUMENTS .....................................................................5

Throttle grip ..........................................................................................5

Right hand brake lever ..........................................................................5

Short circuit button................................................................................6

Left hand brake lever ............................................................................6

Filler cap................................................................................................6

Refueling, fuel .......................................................................................6

Fuel tap .................................................................................................7

Choke (Dell’orto carburetor SHA 1412).................................................7

Choke (Mikuni carburetor VM18-144)..................................................7

Choke (Mikuni carburetor VM20-352)..................................................7

Kickstarter .............................................................................................7

DRIVING INSTRUCTIONS..........................................................................8

What you should check before each start..............................................8

Instructions for the first ride ..................................................................8

Running in.............................................................................................8

Starting when engine is cold..................................................................8

Starting when engine is warm ...............................................................9

What to do when the engine is „flooded“ ............................................9

Starting off ............................................................................................9

Driving ..................................................................................................9

Braking..................................................................................................9

Stopping................................................................................................9

PERIODIC MAINTENANCE SCHEDULE ...................................................10

MAINTENANCE WORK ON CHASSIS AND ENGINE ...............................11

Checking and adjusting the steering head bearing ..............................11

Cleaning the dust scrabbers of the telcopic fork ..................................11

Telescopic fork maintenance................................................................12

Check chain tension ............................................................................13

Correct chain tension...........................................................................13

Chain maintenance..............................................................................13

Adjusting the front wheel brake cable .................................................14

Checking the front brake linings for wear............................................14

Adjusting the rear wheel brake cable...................................................14

Checking the rear brake linings for wear .............................................14

Drum brake maintenance ....................................................................14

Removing and mounting the front wheel............................................15

Removing and mounting the rear wheel .............................................15

Tires, air pressure.................................................................................15

Checking spoke tension.......................................................................15

Removing the seat...............................................................................16

Cleaning the air filter...........................................................................16

Adjusting the throttle cable .................................................................16

Adjusting the idle speed ......................................................................17

Checking the gear oil level ..................................................................17

Changing the gear oil..........................................................................18

Changing the seat hight ......................................................................18

TECHNICAL DATA - ENGINE...................................................................19

TECHNICAL DATA - CHASSIS .................................................................20

INDEX

ENGLISH

KTM mini motorcycles are off-road motorcycles designed for one person only. They are not allowed on public roads.

Motorcycle dimensions and components are designed for the following age and weight groups:

50 MINI ADVENTURE / 50 SX JUNIOR / 50 JR ADVENTURE:

Age 4 - 6 years, maximum weight 35 kg (78 lbs), maximum body height 130 cm (51 in)

50 SX SENIOR / 50 SR ADVENTURE:

Age 7 - 8 years, maximum weight 35 kg (78 lbs), maximum body height 130 cm (51 in)

– Have your youngster wear proper protective gear whenever he or she rides the motorcycle: helmet, eye

protection, chest, back, arm and leg protectors, gloves and boots. To set a good example, be sure to wear

protective gear yourself whenever riding a motorcycle!

– Adjust the hand brake levers to your youngster’s hand size (with gloves).

– Before your youngster takes his or her first ride, explain how each of the controls works and check if your

youngster has understood what you explained. We recommend to review the entire owner’s manual with

your youngster item by item, paying particular attention to the specially marked warnings and pointing out

the danger of injury.

– Instruct your youngster about riding and falling techniques, explain how the motorcycle will respond to

shifting of the rider’s weight, etc.

– Before using the motorcycle you should always check all components for proper operation (see mainenan-

ce schedule). Have your youngster perform these technical checks himself / herself as well.

– Whenever you go for a ride with your youngster, keep in mind that the speed should be adjusted to your

youngster and not the other way around.

– Your youngster must understand that all instructions he or she receives from you or any other supervising

adult must be followed.

– Your child must be physically ready to ride a motorcycle. This means that he or she must at least be able to

ride a bicycle. Being good at sports that require fast reactions is an additional advantage. Your youngster

should be strong enough to pick up the motorcycle after a fall.

– Never demand too much of your youngster. Give him or her time to get used to the motorcycle and to

improve his / her riding skills. Do not even consider letting your youngster participate in a race before

his / her physical condition, riding skills and motivation have sufficiently developed.

– Explain to your youngster that he / she should always adjust his / her riding speed to the local conditions

as well as to his / her own riding skills and that excessive speed can cause falls and severe injuries. Always

keep in mind that youngsters tend to underestimate dangers or fail to recognize them altogether. The riding

speed must be reduced, in particular, on unknown terrain.

– Never let your youngster ride the motorcycle without supervision. An adult should always be present.

– The motorcycle is designed for one rider only. Your youngster is not allowed to transport a passenger.

– When you go for a ride, somebody at home should always know where you are going and when you will

be back. This makes it easier to send you help, should problems occur.

IMPORTANT INFORMATION ON SAFE DRIVING FOR PARENTS

ENGLISH

Chassis number

The chassis number is located on the type plate on the steering head. Write

this number into the field on page no 1.

Engine number

The engine number is stamped into the right half of the engine case next to

the kickstarter. Write this number into the relevant area on page 1.

Engine typ

Motorcycle typ Engine typ

50 Mini Adventure ...........................S5-E

50 SX Junior / JR Adventure ............S5-GS

50 SX Senior / SR Adventure ...........S5-GS

Throttle grip

The throttle grip is located on the right side of the handlebar. It is used to

reduce the engine speed and, thus, the driving speed.

Right hand brake lever

The right hand brake lever is used to operate the front wheel brake via a

control cable.

Use stud 1to adjust the basic position of the hand brake lever to your

youngster's hand size.

CAUTION

AFTER CHANGING THE BASIC POSITION OF THE HAND BRAKE LEVER, ALWAYS CHECK IF THE

FRONT WHEEL IS TURNING EASILY. IF THIS IS NOT THE CASE, READJUST THE BRAKE

CONTROL CABLE.

SERIAL NUMBER LOCATIONS

OPERATION INSTRUMENTS

ENGLISH

Short circuit button

The short circuit button 1turns off the engine. When pressing this button,

the ignition circuit is short-cicuited.

Left hand brake lever

The left hand brake lever is used to operate the rear wheel brake via a

control cable.

Use stud 2to adjust the basic position of the hand brake lever to your

youngster's hand size.

CAUTION

AFTER CHANGING THE BASIC POSITION OF THE HAND BRAKE LEVER, ALWAYS CHECK IF THE

REAR WHEEL IS TURNING EASILY. IF THIS IS NOT THE CASE, READJUST THE BRAKE

CONTROL CABLE.

Filler cap

To open it: turn filler cap counter-clockwise.

To close it: put filler cap back on and tighten it by turning it clockwise.

Install tank breather hose 3without kinks.

Refueling, fuel

Oil (high-grade two-stroke engine oil) must be mixed with the fuel

(ROZ 95) at a mixing ratio of 1:40.



WARNING



GASOLINE IS HIGHLY FLAMMABLE AND POISONOUS. EXTREME CAUTION SHOULD BE USED

WHEN HANDLING GASOLINE. NEVER REFUEL THE MOTORCYCLE NEAR OPEN FLAMES OR

BURNING CIGARETTES. ALWAYS SWITCH OFF THE ENGINE BEFORE REFUELING. BE CAREFUL

NOT TO SPILL GASOLINE ON THE ENGINE OR EXHAUST PIPE WHILE THE ENGINE IS HOT.

WIPE UP SPILLS PROMPTLY. IF GASOLINE IS SWALLOWED OR SPLASHED IN THE EYES, SEEK

A DOCTOR’S ADVICE IMMEDIATELY.

CAUTION

–O

NLY USE PREMIUM-GRADE GASOLINE ROZ 95 MIXED WITH HIGH-GRADE TWO-

STROKE ENGINE OIL. OTHER TYPES OF GASOLINE CAN CAUSE ENGINE FAILURE.

–O

NLY USE KNOWN BRANDS OF HIGH-GRADE 2-STROKE ENGINE OIL (SHELL ADVANCE

RACING X).

–N

OT ENOUGH OIL OR LOW-GRADE OIL CAN CAUSE EROSION OF THE PISTON. WHEN

SING TOO MUCH OIL

THE ENGINE MAY START SMOKING AND FOUL THE SPARK PLUG

–FUEL EXPANDS WHEN ITS TEMPERATURE RISES. THEREFORE DO NOT FILL THE TANK TO

THE TOP. (SEE FIG.)

40 mm

ENGLISH

Fuel tap

The fuel tap 1is located at the front of the motorcycle on the left side of

the tank.

Opening the fuel tap: Turn the knob all the way to the left.

Closing the fuel tap: Turn the knob all the way to the right.

CAUTION

THE FUEL TAP SHOULD BE LOCKED WHENEVER THE MOTORCYCLE IS PARKED. IF THE TAP

IS NOT CLOSED THE CARBURETOR MAY OVERFLOW AND FUEL GET INTO THE ENGINE.

Choke (Dell'Orto carburetor SHA 1412)

The choke lever 2is located on the right side of the carburetor. Squeezing

and engaging the choke lever reduces the air intake of the carburetor, thus

achieving the "rich" fuel air mixture needed for cold starting.

To restore the choke lever to its original position, thus deactivating the

choke, briefly open the throttle all the way.

Choke (Mikuni carburetor VM18-144 / VM 16-519)

The choke lever 3is located on the left side of the carburetor. Squeezing

the lever opens a bore in the carburetor through which the engine can take

in additional fuel, thus achieving the "rich" fuel air mixture needed for cold

starting.

To close the bore in the carburetor simply pull the choke lever upwards into

the original position.

Choke (Mikuni carburetor VM20-364)

When pulling the choke knob 4fully outwards, a bore is opened in the

carburetor. Through this bore the engine can take in additional fuel. This

encoure the rich fuel-air mixture, that is needed for a cold start.

When pressing the choke knob downward in the carburetor, the bore is

closed again.

Kickstarter

The kickstarter is mounted on the right side of the engine. Its upper part can

be swivelled.



WARNING



HEN STARTING THE ENGINE

PUT ON MOTORCYCLE BOOTS IN ORDER TO AVOID INJURIES

YOU MAY SLIP OFF THE KICKSTARTER, OR THE ENGINE MAY STRIKE BACK WHEN KICKING

NOT VEHEMENTLY ENOUGH.

ENGLISH

DRIVING INSTRUCTIONS

– To improve his/her riding skills, your youngster should prac-

tise to ride the motorcycle standing on the footpegs or to

ride at the slowest possible speed. Additionally, you can

arrange a series of obstacles and have your youngster drive

around them, etc.

– Tell your youngster to look 3-10 m ahead, depending on the

speed, to recognize and avoid obstacles. When riding

through curves, the rider should also look far ahead into the

curve.



WARNING



– KTM MINI MODELS ARE DESIGNED FOR ONE PERSON ONLY.

PASSENGERS ARE NOT ALLOWED.

–T

HESE MODELS DO NOT COMPLY WITH THE REGULATIONS AND SAFETY

STANDARDS ESTABLISHED BY THE LAW. THEREFORE, THEY ARE NOT

PERMITTED ON PUBLIC ROADS.

–A

LWAYS KEEP IN MIND THAT OTHER PEOPLE FEEL MOLESTED BY

EXCESSIVE NOISE.

Running in

–EVEN VERY PRECISELY MACHINED SECTIONS OF ENGINE COMPONENTS

HAVE ROUGHER SURFACES THAN COMPONENTS WHICH HAVE BEEN SLI-

DING ACROSS ONE ANOTHER FOR QUITE SOME TIME. THEREFORE,

EVERY ENGINE NEEDS TO BE BROKEN IN. FOR THIS REASON, DURING ITS

FIRST 5 HOURS THE ENGINE MUST NOT BE REVVED UP TO ITS PERFOR-

MANCE LIMITS.

–APPLY LOW BUT CHANGING LOADS FOR RUNNING-IN.

– DO NOT DRIVE AT FULL LOAD FOR THE FIRST 5 HOURS!

Starting when the engine is cold

1 Open fuel tap

2 Operate the choke

3 Swing the side stand all the way up.

4 Squeeze both brake levers.

5 Operate the kickstarter, depressing it all the way, without

opening the throttle.



WARNING



–T

O AVOID INJURY WHEN STARTING THE ENGINE, ALWAYS WEAR BOOTS!

–

HEN STARTING THE ENGINE

ALWAYS KEEP THE BRAKE LEVERS SQUEE

ZED

. A

S SOON AS THE ENGINE IS RUNNING

SLOWLY RELEASE THE BRAKE

LEVERS

. A

N ACTIVATED CHOKE INCREASES THE IDLE SPEED OF THE ENGI

THE CENTRIFUGAL CLUTCH THUS BEGINNING TO ENGAGE

HEREFORE

THE MOTORCYCLE CAN BEGIN TO MOVE WHEN THE BRAKE

LEVERS ARE RELEASED

–THE MOTORCYCLE HAS A CENTRIFUGAL CLUTCH. THE MOTORCYCLE

BEGINS TO MOVE AS SOON AS THE THROTTLE IS OPENED.

–D

O NOT START THE ENGINE AND ALLOW IT TO IDLE IN A CLOSED AREA.

EXHAUST FUMES ARE POISONOUS AND CAN CAUSE LOSS OF CONS-

CIOUSNESS AND DEATH. ALWAYS PROVIDE ADEQUATE VENTILATION

WHILE THE ENGINE IS RUNNING.

What you should check before each start

When you start off, the motorcycle must be in a perfect

technbical condition. For safety reasons, you should make it a

habit to perform an overall check of your motorcycle before

each start.

The following checks should be performed:

1 CHECK TRANSMISSION OIL LEVEL.

A lack of gear oil leads to premature wear and finally results

in destruction of the gear wheels.

2 FUEL

Check that there is sufficient fuel in the tank; when closing the

filler cap, check that the tank venting hose is free of kinks.

3 CHAIN

A loose chain was fall off the chain wheels; an extremely

worn chain may tear, and insufficient lubrication may result

in unnecessary wear of chain and chain wheels.

4 TIRES

Check for damaged tyres. Tires showing cuts or dents must

be replaced. Also check the air pressure. Insufficient tread and

incorrect air pressure deteriorate the driving performance.

5 BRAKES

Check the brakes for proper adjustment and correct operation.

6 Throttle cable

Check the throttle cable for proper adjustment and smooth

operation.



WARNING



–HAVE YOUR YOUNGSTER WEAR PROPER PROTECTIVE GEAR WHENEVER

HE OR SHE RIDES THE MOTORCYCLE: HELMET, EYE PROTECTION, CHEST,

BACK, ARM AND LEG PROTECTORS, GLOVES AND BOOTS. TO SET A

GOOD EXAMPLE, BE SURE TO WEAR PROTECTIVE GEAR YOURSELF

WHENEVER RIDING A MOTORCYCLE!

–O

NLY USE ACCESSORY PARTS RECOMMENDED BY KTM.

Instructions for the first ride

– Verify that your KTM dealer performed the PREPARATION

OF VEHICLE jobs (see Customer Service Manual).

– Before your youngster takes his or her first ride, explain how

each of the controls works and check if your youngster has

understood what you explained. We recommend to review

the entire owner’s manual with your youngster item by item,

paying particular attention to the specially marked warnings

and pointing out the danger of injury.

– Adjust the basic hand brake lever position to your young-

ster's hand size. Your youngster should, of course, wear

gloves!

– To prevent injury, teach your youngster the basic riding skills

on soft ground, e.g. on a meadow or in the garden. Be sure

that there is room enough to maneuver, and that no other

riders are close.

– To ensure that your youngster gets the feel of the brakes,

have your youngster operate the brakes while you push the

motorcycle. Do not start the engine before your youngster

has learned to apply both brakes with appropriate pressure.

– Now your youngster must get the feel of the throttle. Start

the engine, hold the motorcycle and have your youngster

slowly open the throttle. Then, your youngster can take

his/her first ride. Initially, your youngster should ride back

and forth between two persons who help the young rider to

stop the motorcycle. However, you should also teach your

youngster how to stop the motorcycle himself/herself.

ENGLISH

Starting when the engine is warm

1 Open fuel tap

2 Swing the side stand all the way up.

3 Squeeze both brake levers.

4 Operate the kickstarter, depressing it all the way, without

opening the throttle.

What to do when the engine is „flooded”

1 Close fuel tap

2 Squeeze both brake levers.

3 Start engine with full throttle. If necessary, unscrew spark

plug and dry it.

4 Once the engine is running, open fuel tap again.

Starting off

Slowly release the brake lever while simultaneously opening the

throttle.



WARNING



BEFORE YOU START OFF, CHECK THAT THE SIDE STAND HAS BEEN SWUNG

RIGHT UP TO THE TOP. IF THE STAND DRAGS ON THE FLOOR, YOU MAY

LOSE CONTROL OF YOUR MOTORCYCLE.

Driving

The engine speed, and thus the driving speed, are regulated by

the throttle grip.

The choke must always be deactivated as soon as the engine

has warmed up.

If your motorcycle has a Dell'orto carburetor, briefly open the

throttle all the way to restore the choke lever to its original position.

If your motorcycle has a Mikuni carburetor, pull the choke lever

into the original position.



WARNING



–Y

OUR CHILD SHOULD NEVER DRIVE FASTER THAN ITS SKILLS AND THE

TERRAIN PERMIT.

–N

EVER LET YOUR CHILD DRIVE ITS MOTORCYCLE UNCHAPERONED.

–W

HEN THE ENGINE SPEED DROPS TO THE LEVEL AT WHICH THE CENTRI-

FUGAL CLUTCH DISENGAGES, BRAKING WITH THE ENGINE IS NO LON-

GER POSSIBLE AND THE MOTORCYCLE CAN ONLY BE SLOWED DOWN

USING THE BRAKES.

–R

EPLACE THE HELMET VISOR OR GOGGLE GLASSES EARLY ENOUGH.

WHEN LIGHT SHINES DIRECTLY ON A SCRATCHED VISOR OR GOGGLES,

YOU WILL BE PRACTICALLY BLIND.

–A

FTER FALLING WITH THE MOTORCYCLE, CHECK ALL ITS FUNCTIONS

THOROUGHLY BEFORE USING IT AGAIN.

–A

BENT HANDLEBAR MUST ALWAYS BE REPLACED. NEVER TRY TO

STRAIGHTEN THE HANDLEBAR BECAUSE THIS WILL CAUSE IT TO LOSE ITS

STABILITY.

CAUTION

–D

RIVING A COLD ENGINE AT HIGH SPEED WILL REDUCE THE LIFE OF THE

ENGINE. WE RECOMMEND TO WARM THE ENGINE UP AT A MEDIUM

ENGINE SPEED FOR SEVERAL MINUTES BEFORE SWITCHING TO FULL

LOAD.

–W

HILE YOUR ALLOW THE ENGINE TO WARM UP, NEVER LET YOUR

MOTORCYCLE REST ON ITS SIDESTAND IN AN INCLINED POSITION (SEE

PHOTO). THIS INCLINED POSITION MIGHT CAUSE ENGINE FAILURE.

–I

N THE EVENT THAT, WHILE YOUR CHILD IS RIDING ON THE MOTORCY-

CLE, YOU NOTICE ANY UNUSUAL OPERATION-RELATED NOISE, YOUR

CHILD SHOULD STOP IMMEDIATELY, TURN THE ENGINE OFF, AND

CONTACT AN AUTHORIZED KTM DEALER.

Braking

Close the throttle and squeeze both brake levers simultaneous-

ly. On sandy, wet or slippery terrain the rear wheel brake should

be preferred. The brakes should always be operated carefully as

locking wheels can cause skidding or falls.



WARNING



BRAKE DRUM AND LININGS HEAT UP DURING BRAKE OPERATION, THUS

REDUCING THE EFFECT OF THE BRAKES.

Stopping

Reduce the speed. Immediately before the motorcycle comes to

a stop, put the left foot down. To turn off the engine, press the

short circuit button until the engine stops. Close the fuel tap.



WARNING



–NEVER LEAVE YOUR MOTORCYCLE WITHOUT SUPERVISION AS LONG AS

THE ENGINE IS RUNNING.

–MOTORCYCLES PRODUCE GREAT HEAT DURING OPERATION.

THEREFORE, KEEP IN MIND THAT THE ENGINE, THE EXHAUST SYSTEM

AND THE BRAKES CAN HEAT UP CONSIDERABLY. MAKE SURE THAT THESE

PARTS ARE NOT TOUCHED AND ALWAYS TAKE CARE, WHEN PARKING

THE MOTORCYCLE

THAT OTHER PERSONS WILL NOT BURN THEMSELVES

CAUTION

CLOSE THE FUEL TAP WHEN LEAVING THE MOTORCYCLE. OTHERWISE THE

CARBURETOR MAY GET FLOODED AND FUEL WILL ENTER THE ENGINE.

O.K. DON’T

ENGLISH

PERIODIC MAINTENANCE SCHEDULE

Check transmission oil level ●

Change transmission oil ●

Check spark plug and electrode gap ●

Check carburetor for tight fit on the intake flange ●●

Drain and clean carburetor float chamber ●●

Check idle setting when engine is warm ●

Check air filter, filter box and filter boot ●

Check sprockets, chain guides and chain for wear ●●

Clean and lube chain ●● ●

Check chain tension ●●

Check exhaust system for leaks ●●

Check exhaust brackets ●●

Check brake lining thickness ●

Check brake drums ●

Check freeplay and operation of hand brake levers ●●

Check fork for function and tightness ●●

Service front fork completely ●

Check steering head bearing clearance / adjust ●●

Clean and grease steering head bearings ●

Check shock absorber for function and tightness ●●

Check bearings of swingarm for play ●

Clean and grease bearings of swingarm ●

Check tightness of spokes and rim join ●●

Check wheel bearings for clearance ●●

Check tire condition and air pressure ●●

Check cables for damage, correct instalment and easy working ●●

Lube and adjust cables ●●

Check all screws, nuts and hose clamps for proper tightness ●●

Grease or lube all pivot points and sliding components ●●

before each start

after washing

Service after

10 hours

once a year

KTM

rider

KTM

dealer

50 Mini Adventure

50 SX Junior

50 JR Adventure

50 SX Senior

50 RS Adventure

7. 99

ENGLISH

Checking and adjusting the steering head bearing *

The steering head bearing should regularly be checked for play. For this pur-

pose, jack up the motorcycle by the frame so that the front wheel is in the

air. Now try to move the fork forward and backward. There should be no

play. For readjustment, release the two clamp screws 1of the top triple

clamp and the counter nut 2. Turn the adjusting nut 3until almost no play

is left. Do not tighten the adjusting nut! Tightening the adjusting nut can

damage the bearings! Keep in mind that tightening the counter nut 2

reduces the play of the bearing. Slightly tap the top triple clamp with a

rubber hammer to prevent jamming. Then tighten the 2 clamp screws with

15 Nm (11 ft.lb).



WARNING



IF THE STEERING HEAD BEARING IS NOT ADJUSTED TO BE FREE OF PLAY, THE MOTORCY-

CLE WILL EXHIBIT UNSTEADY DRIVING CHARACTERISTICS AND CAN GET OUT OF CONTROL.

CAUTION

–T

HE HANDLEBAR MUST MOVE EASILY. OTHERWISE THE BEARINGS WILL BE DAMAGED.

–I

F YOU DRIVE WITH PLAY IN THE STEERING HEAD BEARING FOR LONGER PERIODS, THE

BEARINGS AND SUBSEQUENTLY THE BEARING SEATS IN THE FRAME WILL BE DESTROYED

At least once a year, the steering head bearings should be smeared with

waterproof grease.

Cleaning the dust scrabbers of the telescopic fork

The dust scrabbers 4should be cleaned on a regular basis.

For this purpose, use a screwdriver to lever the dust scrabbers out of the

slider tubes, clean them thoroughly with compressed air, spray the fork

tubes and dust scrabbers with silicon oil and press the scrabbers back into

the slider tubes.

MAINTENANCE WORK ON CHASSIS AND ENGINE



WARNING



MAINTENANCE WORK AND ADJUSTMENTS MARKED WITH AN ASTERISK (*) MUST BE PERFOR-

MED BY AN EXPERT. TO PROTECT YOUR YOUNGSTER, ALWAYS HAVE SUCH WORK PERFORMED

BY A SPECIALIZED KTM DEALER.

CAUTION

–W

HEN CLEANING THE MOTORCYCLE, DO NOT USE A HIGH PRESSURE CLEANING UNIT IF POSSIBLE, OTHERWISE WATER WILL PENETRATE THE

BEARINGS, CARBURETOR, ELECTRIC CONNECTORS ETC.

–W

HEN TRANSPORTING YOUR MOTORCYCLE, SECURE IT WITH ELASTIC STRAPS OR OTHER MECHANICAL DEVICES IN AN UPRIGHT POSITION.

BE SURE THAT THE FUEL TAP IS CLOSED. IF THE MOTORCYCLE TOPPLES OVER, FUEL CAN FLOW OUT OF THE CARBURETOR OR FUEL TANK.

–D

O NOT USE TOOTHED WASHERS OR SPRING RINGS WITH THE ENGINE FASTENING SCREWS, AS THESE WORK INTO THE FRAME PARTS AND KEEP

WORKING LOOSE. INSTEAD, USE SELF-LOCKING NUTS.

–L

ET YOUR MOTORCYCLE COOL DOWN BEFORE BEGINNING ANY MAINTENANCE WORK IN ORDER TO AVOID GETTING BURNED.

–R

EMOVE OILS, FATTY MATTERS, FILTERS, FUELS, WASHING DETERGENTS ETC. ORDERLY.

–U

NDER NO CIRCUMSTANCES MAY USED OIL BE DISPOSED OF IN THE SEWAGE SYSTEM OR IN THE OPEN COUNTRYSIZE. 1 LITER USED OIL

CONTAMINATES 1.000.000 LITERS WATER.

ENGLISH

Telescopic fork maintenance (50 Mini Adventure) *

The telescopic fork must be serviced at least once a year:

– Jack up the motorcycle by the frame to take the weight off the front

wheel.

– Remove the front wheel and the brake cable guide.

– Release the clamp screws 1at the triple clamps and pull the fork legs

downwards out of the triple clamps.

– Clamp the fork leg into a vise (use protective jaws) and remove the

plugs 2.

– Take the preload spacer and the spring out of the fork tube.

– Remove screws 3at the underside of the slider tubes and pull the fork

tubes out of the slider tubes.

– Remove the dust scrabbers 4.

– Thoroughly clean all parts and check for wear.

– Grease gaskets and springs and reassemble the telescopic fork.

– Tighten the screws at the underside of the slider tubes with 30 Nm

(22 ft.lb).

– Insert the fork legs into the triple clamps (the fork tube must be flush

with the top triple clamp) and tighten the clamp screws with 15 Nm

(11 ft.lb).

– Mount the front wheel.

Changing the telescopic fork oil *

(50 SX Junior, 50 JR Adventure, 50 SX Senior, 50 SR Adventure)

– Remove front wheel and fork legs (see above).

– Remove plugs, preload spacers and springs.

– Drain the fork oil into an appropriate container.

– Clean the dust scrabbers.

– Fill the fork tubes with new fork oil (SAE 7.5)

50 SX Junior, 50 JR Adventure: 150 ccm per fork tube

50 SX Senior, 50 SR Adventure: 160 ccm per fork tube

– Insert springs and preload spacers into the fork tube.

– Check and grease O-rings and mount the plugs.

– Mount fork legs and front wheel (see above), then mount the cable

guide.

ENGLISH

Check chain tension

– Put the motorcycle on the sidestand.

– Check the chain tension approximately in the middle between the two

chain guides Aand B. In this area, the chain should easily move appro-

ximately 10 mm (0.4 in) upward and downward.

– If necessary, correct chain tension.



WARNING



–IF CHAIN TENSION IS TOO GREAT, PARTS WITHIN THE SECONDARY TRANSMISSION

(CHAIN, CHAIN WHEELS, GEAR BOX AND REAR WHEEL BEARINGS) WILL BE SUBJECTED

TO UNNECESSARY STRESS

RESULTING IN PREMATURE WEAR AND EVEN CHAIN BREAKAGE

–TOO MUCH SLACK IN THE CHAIN, ON THE OTHER HAND, CAN RESULT IN THE CHAIN

JUMPING OFF THE CHAIN WHEELS. IF THIS HAPPENS, THE CHAIN COULD ALSO BLOCK

THE REAR WHEEL OR DAMAGE THE ENGINE.

–I

N EITHER CASE THE OPERATOR IS LIKELY TO LOSE CONTROL OF THE MOTORCYCLE.

Correct chain tension

– Release the hexagon nut of the wheel spindle 1and turn the left and

the right hexagon nut 2equally far.

– Before tightening the hexagon nut of the wheel spindle with 30 Nm

(22 ft.lb), ensure that the supporting plates 3are resting against the

swing arm. Additionally, check that the rear wheel is aligned with the

front wheel.

Chain maintenance

For long chain life, good maintenance is very important. Chains without

O-rings should be cleaned in fireproof solvent regularly and afterwards

treated with hot grease or chain spray (Shell Advance Bio Chain).



WARNING



KEEP THE REAR WHEEL FREE OF GREASE! GREASE ON THE REAR WHEEL WILL SIGNIFICANTLY

REDUCE THE GRIP OF THE REAR TIRE AND THE MOTORCYCLE COULD EASILY GET OUT OF CONTROL

CAUTION

WHEN MOUNTING THE CHAIN MASTERLINK CLIP, THE CLOSED SIDE OF THE MASTERLINK

CLIP MUST POINT IN RUNNING DIRECTION.

Also check sprockets and chain guides for wear, and replace if necessary.

10 m m

✓

ENGLISH

Adjusting the front wheel brake cable

The hand brake lever should travel between 10 and 15 mm (0.4-0.6 in)

before the front wheel is actually slowed down.

To adjust the brake control cable, use either the adjusting screw 1at the

hand brake lever or the adjusting screw 2at the brake backing plate. Before

commencing to adjust the cable, always release the counter nut 3.

Afterwards, the counter nut must be retightened.

CAUTION

AFTER ADJUSTING THE CABLE, ALWAYS CHECK IF THE WHEEL TURNS SMOOTHLY.

Checking the front brake linings for wear

The brake linings must be replaced when the distance between the hub

brake lever and the cable support, measured with the brake lever squeezed,

is less than 50 mm (2 in) (see illustration).

CAUTION

IF THE BRAKE LININGS ARE REPLACED TOO LATE, I.E. WHEN THE LINING IS PARTLY OR

FULLY WORN AWAY, THE METAL SHOES WILL RUB AGAINST THE BRAKE DRUM, THUS

REDUCING THE BRAKING EFFECT AND DESTROYING THE BRAKE DRUM.

Adjusting the rear wheel brake cable

The hand brake lever should travel between 10 and 15 mm (0.4-0.6 in)

before the rear wheel is actually slowed down.

To adjust the brake control cable, use eigher the adjusting screw 4at the

hand brake lever or the adjusting screw 5at the brake backing plate. Before

commencing to adjust the cable, always release the counter nut 6.

Afterwards, the counter nut must be retightened.

CAUTION

AFTER ADJUSTING THE CABLE, ALWAYS CHECK IF THE WHEEL TURNS SMOOTHLY.

Checking the rear brake linings for wear

The brake linings must be replaced when the distance between the hub

brake lever and the cable support, measured with the brake lever squeezed,

is less than 50 mm (2 in) (see illustration).

CAUTION

IF THE BRAKE LININGS ARE REPLACED TOO LATE, I.E. WHEN THE LINING IS PARTLY OR

FULLY WORN AWAY, THE METAL SHOES WILL RUB AGAINST THE BRAKE DRUM, THUS

REDUCING THE BRAKING EFFECT AND DESTROYING THE BRAKE DRUM.

Drum brake maintenance

Drum brake maintenance is limited to occasional blowing out of brake drum

and brake shoes. Brake drum and brake linings can be slightly roughened

with an abrasive cloth.

min 50 mm

10-15 mm

ENGLISH

Removing and mounting the front wheel

– Jack up the motorcycle by the frame.

– Remove the right hexagon nut of the wheel spindle 1together with the

washer.

– Pull the wheel spindle halfway out and remove the spacer 2.

– Now pull out the wheel spindle out until the wheel is free but not so far

that the brake backing plate comes off.

– Turn both wheel and fork slider tube to the left and remove wheel.

– To mount the wheel reverse the procedure described above.

– Tighten the hexagon nut with 30 Nm (22 ft.lb).

Removing and mounting the rear wheel

– Jack up the motorcycle by the frame.

– Remove the right hexagon nut of the wheel spindle 3together with the

washer.

– Hold the rear wheel and remove the wheel spindle.

– Move the rear wheel downward, remove the chain and take the rear

wheel out of the swing arm.

– To mount the wheel reverse the procedure described above.

– Always hook the brake backing plate into the swing arm support.

– Before tightening the hexagon nut of the wheel spindle, ensure that the

supporting plates 4are resting against the swing arm. Additionally,

check that the rear wheel is aligned with the front wheel.

– Tighten the hexagon nut with 30 Nm (22 ft.lb).

Tires, air pressure

Tire type, tire condition, and air pressure level affect the way your motorcy-

cle rides, and they must therefore be checked whenever you are getting

ready to go anywhere on your motorcycle.

– Tire size can be found in the technical specifications.

– Tire condition has to be checked every time you want to ride your

motorcycle. Before leaving, check tires for punctures and nails or other

sharp objects that might have become embedded in them.

– Regularly check the "cold" tire pressure. Correct tire pressure (1.0 bar /

14 psi) guarantees optimum grip and maximum tire life.



WARNING



–DAMAGED TIRES MUST BE REPLACED IMMEDIATELY TO PROTECT YOUR YOUNGSTER.

–W

ORN TIRES CAN HAVE A NEGATIVE EFFECT ON HOW THE MOTORCYCLE PERFORMS,

ESPECIALLY ON WET SURFACES

–TIRE PRESSURE BELOW THE NORMAL LEVEL WILL LEAD TO PREMATURE TIRE WEAR.

Checking spoke tension

The correct spoke tension is very important for the stability of the wheels

and thus for riding safety. A loose spoke causes the wheel to become

unbalanced and before long other spokes will have come loose. Check

spoke tension, especially on a new motorcycle, in regular intervals. If neces-

sary, have the spokes retightened and the wheel centered by a KTM dealer.



WARNING



POKES CAN TEAR IF YOU CONTINUE TO RIDE WITH THEM LOOSE

. T

HIS MAY LEAD TO AN

UNSTABLE HANDLING OF YOUR MOTORCYCLE

ENGLISH

Removing the seat

The quick-release mechanism 1allows removal of the seat without tools.

Turn the quick-release device approximately 180° anticlockwise, lift the rear

portion of the seat and pull the seat off backwards.

When mounting the seat ensure that the hook 2engages at the tank.

Cleaning the air filter *

The air filter must be cleaned at intervals depending on the amount of dust

accumulated. To clean the air filter, first remove the seat. Then remove the

two screws 3, the filter holder and the air filter 4. The air filter consists of

a foam rubber insert soaked with filter oil.

CAUTION

–D

O NOT CLEAN FOAM FILTER WITH FUEL OR PETROLEUM SINCE THESE WILL DAMAGE

THE FOAM. KTM RECOMMENDS THE PRODUCTS MADE BY PUTOLINE FOR AIR FIL-

TER MAINTENANCE.„ACTION CLEANER” FOR CLEANING PURPOSES AND „ACTION

FLUID” TO OIL THE FOAM FILTER.

–NEVER OPERATE YOUR MOTORCYCLE WITHOUT AIR FILTER. OTHERWISE, DUST AND

DIRT MAY GET INTO THE ENGINE AND LEAD TO INCREASED WEAR.

Thoroughly wash the foam filter in special cleaning fluid and allow it to dry

well. Only press out the filter, do not wring it out under any circumstances.

Oil the dry foam filter with a high-grade filter oil. Also clean the air filter

box. Check carburetor collar for damage and that it is filled correctly.

Insert the air filter in the opening and fasten it with the filter holder. Then

mount the seat.

Adjusting the throttle cable *

There must always be a 3-5 mm (0.1-0.2 in) play in the throttle cable. To

check this, move back the protective cover 5on the throttle grip. You must

be able to lift the outer covering of the cable 3-5 mm from the adjusting

screw 7, until resistance is felt.

To adjust, loosen the counter nut 6and turn the adjusting screw accor-

dingly. Finally tighten counter nut and slide the protective cover back on.

3-5 mm 5

ENGLISH

Adjusting the idle speed (Dell’Orto SHA 1412) *

The idle speed can be adjusted with throttle stop screw 1.

Turning in clockwise direction will increase the idle speed.

Turning in counterclockwise direction will reduce the idling speed.

Adjusting the idle speed (Mikuni VM18-144 / 16-519) *

The idle speed can be adjusted with throttle stop screw 2.

Turning in clockwise direction will increase the idle speed.

Turning in counterclockwise direction will reduce the idling speed.

Adjusting the idle speed (Mikuni VM20-364) *

The idle speed can be adjusted with throttle stop screw 3.

Turning in clockwise direction will increase the idle speed.

Turning in counterclockwise direction will reduce the idling speed.

Checking the gear oil level

To check the gear oil level, first remove the plug 4. With the motorcycle

parked in an upright position, a small quantity of oil should flow out of the

indicator opening 5. If oil must be added, tilt the motorcycle and pour gear

oil SAE 30 (ex. Shell Advance VSX 4) into the opening.

CAUTION

TOO LITTLE OIL OR A POOR OIL QUALITY LEAD TO PREMATURE TRANSMISSION WEAR.

THEREFORE, ONLY USE BRANDED PRODUCTS (EX. SHELL ADVANCE VSX 4).

ENGLISH

Changing the gear oil *

The engine must be warmed up before changing the gear oil. Park the

motorcycle on a horizontal surface, remove the oil drain plug 1and drain

the used oil into an appropriate container. Clean the sealing surface, mount

the oil drain plug together with the gasket and tighten with 15 Nm (11 ft.lb).

Lay the motorcycle on its side and add 0.25 l gear oil SAE 30 (ex. Shell

Advance VSX 4). Mount the plug 3and check the engine for leaks.

CAUTION

TOO LITTLE OIL OR A POOR OIL QUALITY LEAD TO PREMATURE TRANSMISSION WEAR.

THEREFORE, ONLY USE BRANDED PRODUCTS.

Changing the seat height

The seat height of all 50 mini models can easily be increased by 25 mm (1 in).

The frame is provided with additional fastening points on which the tank

and the tail can be mounted. Thus, you can easily adjust the seat height as

your youngster grows.

25 mm

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KTM 50 MINI ADVENTURE Owner's manual

Brand: KTM

Model: 50 MINI ADVENTURE

Category: Motorcycles

Type: Owner's manual

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